Apparatus and method for producing customised containers of cigarettes

ABSTRACT

Cigarettes are stored in one or more reservoirs at a customer location. A computer receives customer orders and transmits them to a dispenser. Upon receipt of a customer order, a pre-selected number of cigarettes is automatically removed from the reservoir(s) by the dispenser and then automatically packed in a container by a packer comprising a collation mandrel which is movable relative to the dispenser. A preferred type of substantially air-tight, self-sealing container has a lid portion, a body portion and a collar, which is mounted within the body portion. The body portion is provided with one or more upwardly extending protrusions on the upper surface of the base thereof. An air and moisture impermeable membrane is sealed about the upper periphery of the collar.

This application is a national stage application under 35 USC §371 ofInternational Application Number PCT/GB2005/003136, filed August 10,2005, the international Application being published in English. Thisapplication also claims priority under 35 USC §119 to EuropeanApplication No. 04254823.0, filed August 11, 2004.

BACKGROUND OF THE INVENTION

The invention relates to an apparatus and a method for producing acustomized container of cigarettes.

Cigarettes are produced and sold in a wide variety of types. Forexample, different types of tobacco having unique characteristic flavorsand aromas, such as Burley, Oriental and Virginia tobacco, are usedalone or in varying amounts in tobacco blends to produce brands ofcigarettes having different characteristic flavors. In addition, bothplain cigarettes and cigarettes having many different types of filtertips are manufactured as well as cigarettes of differing length,circumference, strength of flavor, total particulate matter delivery andnicotine delivery. Furthermore, cigarettes containing flavorings such asmenthol are also available.

Conventionally, consumers have only been able to obtain cigarettes of aparticular type by purchasing a pack containing cigarettes of that typealone. In normal production, cigarettes of a single type are placed andsealed in a pack at a factory and the finished pack is then shipped to aremote point of sale such as a vending machine or retail outlet where itis purchased by the consumer. Consequently, customers wishing to smokedifferent types of cigarettes on different occasions have typically hadto purchase more than one pack of cigarettes.

EP-A-0 141 629 discloses a process and apparatus for producing a pack ofcigarettes comprising two distinct groups of cigarettes, each groupcomprising cigarettes of a different type. The two distinct groups ofcigarettes are dispensed from a single hopper which is divided into twocompartments by a central partition, each compartment being fed withcigarettes of only one type. Groups of cigarettes dispensed from each ofthe two compartments of the hopper are wrapped separately before beingpacked together in a single conventional cigarette pack.

Although the process and apparatus described in EP-A-0 141 629 enablethe production in a factory of packs comprising two different types ofcigarettes, they do not enable a cigarette pack to be produced in situat the point of sale in response to an individual order. Consequently,the process and apparatus described in EP-A-0 141 629 still suffer fromthe disadvantage that they do not allow the contents of a container ofcigarettes to be tailored or customized in accordance with an individualcustomer's particular tastes or requirements.

SUMMARY OF THE INVENTION

According to the invention there is provided apparatus for theproduction of a customized container of cigarettes at a customerlocation, the apparatus comprising: a reservoir for storing cigarettesat the customer location; a dispenser for automatically removing apre-selected number of cigarettes from the reservoir at the customerlocation in response to a customer order; computing means adapted toreceive a customer order at the customer location and to transmit thecustomer order to the dispenser; and a packer for automatically packingthe removed pre-selected number of cigarettes into a container at thecustomer location.

According to the invention there is also provided a method of producinga customized container of cigarettes at a customer location comprising:providing a reservoir of cigarettes at the customer location;automatically removing a pre-selected number of cigarettes from thereservoir in response to a customer order; and packing the removedpre-selected number of cigarettes into a container.

The term customer location is used throughout the specification to meanany point of disposal of cigarettes to a consumer whether by sale orotherwise, such as, for example, a cigarette kiosk, brand store, dutyfree shop or other point of sale, or a hospitality lounge, promotionalstand or other point of distribution.

Preferably, the apparatus of the invention comprises two or morediscrete reservoirs for storing cigarettes at the customer location,each reservoir being separately provided with means for supplyingcigarettes thereto. Preferably, each reservoir is separately providedwith means of supplying cigarettes of a single type thereto. If desired,however, one or more of the plurality of reservoirs may be provided withmeans for supplying a mixture of two or more different types ofcigarette thereto to allow a customer to order a container completely orpartially filled with an unspecified assortment or “lucky dip” ofcigarettes types. It will be appreciated that for the purposes of thepresent invention, two or cigarettes may be regarded as being ofdifferent types if they differ in, for example, one or more of the waysdiscussed in the opening paragraphs of the specification.

Preferably, each reservoir of the apparatus of the invention is providedwith one or more removable cartridges for supplying cigarettes thereto.The reservoir(s) may be, for example, hoppers or any other receptaclesuitable for storing cigarettes. Preferred embodiments of the apparatusof the invention include up to 10 discrete reservoirs.

Preferably, where the apparatus of the invention comprises two or morediscrete reservoirs, the two or more discrete reservoirs are adapted tomove relative to the dispenser.

By producing individual containers of cigarettes automatically on demandat a customer location, the method and apparatus of the invention allowa customer to order a container holding a desired number of cigarettes.Furthermore, through the provision of a plurality of discrete reservoirsof cigarettes at the customer location, embodiments of the method andapparatus of the invention also allow a customer to order a containerholding desired quantities of two or more different types of cigarette.Since, in contrast to the process and apparatus described in EP-A-0 141629, the method and apparatus of the invention enable a pack to beproduced in situ at the point of sale or distribution in response to anindividual order or request, they allow the contents of a container ofcigarettes to be tailored or customized in accordance with an individualcustomer's particular tastes or requirements.

Preferably, the packer of the apparatus of the invention furthercomprises means for sealing the container, more preferably the packercomprises means for sealing the container under at least a partialvacuum. By sealing the customized container of cigarettes under at leasta partial vacuum, embodiments of the apparatus and method of theinvention advantageously maintain the freshness of the cigarettestherein prior to opening of the container by the consumer.

To provide visual interest to customers, the apparatus of the inventionis preferably at least partially formed from transparent material(s). Atleast partial formation of the reservoir(s) of the apparatus fromtransparent material advantageously enables customers to see the varietyof cigarettes on offer and to inspect their quality before placing anorder. In addition, at least partial formation of the remainder of theapparatus from transparent material advantageously allows customers towatch ordered customized containers of cigarettes being produced. Itwill be appreciated, however, that the apparatus of the invention mayalso be formed from opaque or semi-transparent materials and/or thatopaque or semi-transparent manufacturer or brand logos, trade marks,slogans or other indicia may be applied to the external surface thereof.

Preferably, the apparatus of the invention further comprises storagemeans for storing a plurality of containers at the customer location.More preferably, the apparatus of the invention further comprisesstorage means for storing two or more different types of container atthe customer location. Preferably, the packer comprises means forautomatically removing a container of a pre-selected one of the two ormore different types from the storage means in response to the customerorder. The different types of container may be made from one or moredifferent materials, such as cardboard, plastic or metal, and/or be ofdifferent size and/or cross-section, such as rectangular, square, oval,round or triangular.

By providing a plurality of different types of container at the customerlocation, embodiments of the method and apparatus of the inventionadvantageously allow a customer to select a container of a desired type.For example, individually customized containers of ten or twentycigarettes as well as hinged lid, rounded corner and oval containers ofcigarettes may be produced at a customer's request by embodiments of themethod and apparatus of the invention.

Preferably, the computing means of the apparatus of the invention isprovided with a pre-programmed set of customer orders for selection bythe customer. For example, the computing means may comprise a terminalfor receiving customer orders that offers a number of pre-programmedcombinations of container type, size and shape and/or quantities andtype of cigarette for the customer to select using an interactive touchscreen.

The arrangement of a bundle of cigarettes for packaging is commonlyreferred to as a collation. Preferably, the packer of the apparatus ofthe invention comprises a collation mandrel for receiving cigarettesremoved from the reservoir by the dispenser at the customer location,the collation mandrel being adapted to move relative to the dispenser.In use, a collation of cigarettes is formed in the collation mandrel andthen packed into a container.

A preferred substantially air-tight, self-sealing container for use withapparatus and method of the invention comprises a lid portion, a bodyportion and a collar, mounted within the body portion, having asubstantially air and moisture impermeable membrane affixed to the uppersurface thereof.

In use, the collar of the preferred container surrounds the upper endsof the cigarettes therein. Where the preferred container comprises twoor more different types of cigarette, the interior of the collar ispreferably divided into two or more compartments, each of which, in use,contains cigarettes of only one of the two or more different types.

Preferably, the preferred container comprises means mounted at the baseof the body portion for raising the upper end of one or more of thecigarettes in the container relative to the upper ends of othercigarettes therein. Elevation of one or more of the cigarettes in thecontainer relative to the other cigarettes therein advantageouslyenables the customer to easily remove the elevated cigarettes from thecontainer.

The substantially air and moisture impermeable membrane may be affixedto the upper surface of the collar by a re-sealable adhesive.

Customized containers of cigarettes produced by the method and apparatusof the invention may be marked with an identification mark, such as abar code or graphic symbol, to identify each customized container ofcigarettes produced with a particular customer or customer order.

The invention will be further described by way of example with referenceto the accompanying drawings in which:

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 shows a perspective view of apparatus for producing a customizedpack of cigarettes according to the invention;

FIG. 2 shows an enlarged perspective view of the circled portion of theapparatus of FIG. 1; and

FIG. 3 shows an exploded perspective view of an embodiment of apreferred type of container for use with the apparatus of FIGS. 1 and 2.

DETAILED DESCRIPTION OF THE INVENTION

The apparatus according to the invention shown in FIG. 1 comprises apair of adjacent five-station indexing dispensing carousels 2, which aremounted for rotation about a pair of parallel vertical axes on thehorizontal upper surface of an enclosed frame 4. Five, equally spaced,vertical hoppers 6 are mounted around the lower periphery of eachdispensing carousel 2 at the five stations thereof, such that thelongitudinal axes of the hoppers 6 lie parallel to the axis of rotationof the dispensing carousels 2. Five equally spaced elongate removablecartridges 8 are mounted around the upper periphery of each dispensingcarousel 2, directly above the five hoppers 6, such that thelongitudinal axes of the cartridges 8 also lie parallel to the axis ofrotation of the dispensing carousels 2.

The cartridges 8 are closed at their lower end by a pair of interlockingflaps and are filled with cigarettes using separate apparatus (notshown), which may advantageously be installed at a remote cigaretteproduction facility, and then manually mounted on the dispensingcarousels 2 at the customer location by an operator. Each filledcartridge 8, which may be made from a transparent material such aspolyethylene terephthalate (PET), is preferably separately over wrappedwith an air and moisture impermeable material, such as orientatedpolypropylene (OPP) that is removed by the operator at the customerlocation before the cartridge 8 is mounted on the dispensing carousel 2.

The maximum number of cigarettes each cartridge 8 may contain is, ofcourse, determined by the dimensions of the cartridge 8. 100 mm wide by90 mm deep by 250 mm high cartridges may, for example, be employed wherethe maximum capacity of the cartridges 8 is desired to be about 1000conventional size cigarettes.

The ten hoppers 6 of the apparatus shown in FIG. 1 are identical to oneanother and of known configuration. Each hopper 6 is closed off at thebase and has side walls that taper inwards from top to bottom. The lowerportion of each hopper 6 is divided into a number of generally upwardlyextending channels by a set of spaced apart vanes (not shown). Thespacing between adjacent vanes, and hence the width of each channel, isslightly greater than the diameter of a single cigarette so thatcigarettes with their longitudinal axes aligned horizontally, descendingvertically through the hopper 6 from the cartridge 8, stack up in singlecolumns on the base thereof within the channels. Oscillating agitators(not shown) are mounted above the vanes within each hopper 6 to ensureregular flow of cigarettes through the hopper 6 into the channels.

Each hopper 6 additionally comprises means (not shown) for automaticallyopening the interlocking flaps at the lower end of a cartridge 8, oncethe cartridge 8 has been mounted above it on the dispensing carousel 2,to allow the cigarettes contained therein to fall under gravity throughthe hopper 6 into the channels formed between the vanes thereof.

Each dispensing carousel 2 with its associated five hoppers 6 and fivecartridges 8 is housed in a cabinet 10, the temperature and humiditywithin which is regulated by the control system (not shown) of theapparatus. In addition to regulating the temperature and humidity withinthe cabinets 10, the control system also regulates and transformsincoming power to the apparatus to the appropriate levels required bythe power and logic systems therein. To show the position of the hoppers6 and cartridges 8 on the dispensing carousels 2, the lower part of thecabinet 10 surrounding one dispensing carousel 2 of the apparatus shownhas been removed in FIG. 1. In preferred embodiments, the cabinets 10and hoppers 6 of the apparatus shown in FIGS. 1 and 2 are madesubstantially from transparent material to provide visual interest tocustomers and the cabinets 10 contain a lighting system to improve thevisibility of the contents thereof.

Three sets of detectors (not shown), which are coupled to the controlsystem of the apparatus, are also housed in each cabinet 10. The firstset of detectors comprises five separate detectors mounted at eachstation of the dispensing carousel 2 of a known type capable of readinga bar code or other identifying mark applied to the external surface ofan article. The first set of detectors are mounted proximate the top ofeach of the five cartridges 8 mounted on the dispensing carousel 2 and,in use, read identifying marks applied to the rear of each cartridge 8which identify the type of cigarettes contained therein. Duringproduction, the control system of the apparatus uses this information todrive the indexing dispensing carousel 2 to the correct position todispense cigarettes from a hopper 6 supplied by a cartridge 8 containingthe type of cigarettes ordered by a customer. The control system therebyensures that even where, a cartridge 8 containing an incorrect type ofcigarettes has been loaded at a particular station on the dispensingcarousel 2 by an operator, the cigarettes dispensed from the dispensingcarousel 2 to form the customized container are of the type or typesordered by the customer.

The second set of detectors also comprises five separate detectors, oneof which is mounted inside the upper portion of each of the five hoppers6 on the dispensing carousel 2. The second set of detectors may compriseany known type of detector capable of sensing whether the channelsbetween the vanes of the hoppers 6 are full, such as, for example, astandard weighted pivoting finger system.

Finally, the third set of detectors comprises a plurality of detectorsmounted in the channels between the vanes of the five hoppers 6, whichare of a known type capable of sensing the absence of an article or thepresence of a defective article. In use, the third set of detectorsinspect the tobacco end of cigarettes passing between the vanes of thehoppers 6 for loose ends and/or the filter ends of the cigarettes fordiscoloration or the absence of a filter. Preferably, the third set ofdetectors comprises optical detectors that measure the light reflectedfrom the ends of the cigarettes.

The apparatus of FIG. 1 further comprises a ball screw slide way 12,mounted in front of the two dispensing carousels 2 on the upper surfaceof the frame 4, on which a carriage 14 is mounted for horizontalmovement in the X-direction relative to the dispensing carousels 2. Afour-station rotary indexing turret 16 is mounted for vertical movementin the Y-direction on a vertical slide way 18 that is fixedly mounted onthe carriage 12. Four arms radial arms 20 are spaced at 90° intervalsaround the turret, which is mounted for rotation about a horizontal axisperpendicular to the direction of movement of the carriage 14.

A hollow, elongate split mandrel 22 is mounted on the end of each arm 20of the turret 16 by a 90° rotating valve, for independent rotationalmovement between a first position in which the longitudinal axis of thesplit mandrel 22 is horizontal, perpendicular to the direction ofmovement of the carriage 14, and a second position in which thelongitudinal axis of the split mandrel 22 is vertical. For simplicity,in FIGS. 1 and 2 only two arms 20 and associated split mandrels 22 ofthe apparatus are shown. It will be appreciated, however, that thegeneral construction and mode of operation of the other two arms andassociated split mandrels of the apparatus are identical to those of thearms 20 and split mandrels 22 shown. With reference to FIG. 2, eachsplit mandrel 22 comprises a pair of hinged jaws 24 with a profiledinner surface, which may be opened and re-closed, independently of thejaws 24 of the remaining split mandrels 22, by a mechanism andelectrical actuator (not shown).

Horizontal, reciprocating inserter rods (not shown), equal in number tothe number of channels in the lower portion of each of the hoppers 6,are mounted for movement in the Z-direction at the front station of eachindexing dispensing carousel 2 proximate the ball screw slide way 12.The inserter rods are mounted between each dispensing carousel 2 and therear of the hopper 6 at the front station thereof, in line with thetransverse axes of the channels of the hopper 6. When actuated by, forexample, a servo motor, a reciprocating inserter rod pushes the bottommost or final cigarette in a column of cigarettes in one of the channelsof the hopper 6 along its longitudinal axis towards the slide way 12. Sothat, in use, the reciprocating inserter rods push on the filter end,rather than the tobacco end, of filter cigarettes, cartridges 8containing filter cigarettes are mounted on the dispensing carousel 2with the filter ends of the cigarettes radially inward and the tobaccoends radially outward.

The way in which a number of parallel cigarettes must be groupedtogether or collated in order to fit within a particular containerdepends upon the cross-sectional shape of that container. For example,in a conventional, rectangular hinge-lid pack of twenty cigarettes thecigarettes are arranged in a nested 7-6-7 collation, while in an ovalhinge-lid pack of twenty cigarettes the cigarettes are arranged in a4-6-6-4 collation.

In use, rows of cigarettes pushed clear of the vanes of the hoppers 6 ofthe apparatus of FIGS. 1 and 2 by the reciprocating inserter rods of theapparatus of FIGS. 1 and 2 are received by the split mandrels 22, whichare positioned in line with the inserter rods at the front station ofthe dispensing carousels 2 by the ball screw slide way 12, verticalslide way 18 and turret 16, to form collations of cigarettes which arethen packed into individual containers of corresponding cross-sections.The number of channels in each hopper 6, and hence the number ofinserter rods mounted at the front station of each dispensing carousel 2is equal to, or greater than, the maximum number of cigarettes in anyrow of the collations formed by the four split mandrels 22. For example,where all of the split mandrels 22 of the apparatus of FIGS. 1 and 2 areconfigured to form a 7-6-7 collation of twenty cigarettes for insertioninto a conventional, rectangular hinge-lid pack, each hopper 6 has atleast seven channels and a corresponding number of inserter rods aremounted at the front station of each dispensing carousel 2. The inserterrods are coupled to one another and the control system of the apparatusso that they may be actuated together as a group or in a number ofsub-groups, each of which contains a different number of adjacentinserter rods. The number of inserter rods in each sub-group is equal tothe number of cigarettes in a row of a collation of cigarettes formed bythe split mandrels 22.

By way of example only, it will be assumed that, in use of the apparatusof FIGS. 1 and 2, customers may order four different types of container,each having a different cross-section, and that the inner surfaces ofthe jaws 24 of the four split mandrels 22 of the apparatus are profiledto closely match four different collations of cigarettes, correspondingto the four different cross-sections of the containers.

By way of example only, it will also be assumed that the customer mayalso choose from five different brands of filter cigarette and that eachdispensing carousel 2 has cartridges 8 containing these five brands ofcigarettes mounted thereon.

In use, a customer selects a container from the four different typesavailable and then selects the brand of filter cigarette they want ineach row of the required collation of cigarettes for a container of thatcross-section. Following receipt of the customer order, the turret 16 isindexed by the control system until the longer transverse axis of thesplit mandrel 22 with jaws 24 having a profiled inner surface closelymatching the collation corresponding to the cross-section of theselected container is horizontal. The ball screw slide way 12 is thendriven under computer control to move this split mandrel 22 in front ofone of the cabinets 10, while the vertical slide way 18 is motor drivento align the inner profiled surface of the lower jaw 24 of the splitmandrel 22 with the inserter rods at the front station of the dispensingcarousel 2 therein.

Once the split mandrel is in position, the reciprocating inserter rodsare actuated as a group or sub-group to push a first row of cigarettes,containing a number of cigarettes equal to that in the first row of therequired collation, from the bottom of the columns in the channels ofthe hopper 6 along their longitudinal axis out of the vanes and into thesplit mandrel 22. Once the row of cigarettes has been inserted and theinserter rods retracted to their starting positions, the columns ofcigarettes in the channels of the hopper 6 move down under gravity sothat the penultimate cigarettes in the columns come into alignment withthe inserter rods.

The vertical slide way 18 and, where necessary, ball screw slide way 12are then driven under computer control to line the split mandrel 22 upin the correct position relative to the inserter rods to receive thenext row of the collation of cigarettes required for the container ofcigarettes ordered by the customer. Once the split mandrel 22 is inposition, the inserter rods are actuated as a group or sub-group toinsert a second row of cigarettes, containing a number of cigarettesequal to that in the second row of the required collation, from thehopper 6 into the split mandrel 22 on top of the first row of cigarettestherein. The steps of repositioning the split mandrel 22 relative to theinserter rods and actuating the inserter rods to push a row ofcigarettes into the split mandrel 22 are repeated until the splitmandrel 22 contains the complete collation of cigarettes required forthe container of cigarettes ordered by the customer. Thus, in use, theinserter rods are static in the X-Y plane, but move in the Z-direction,while the split mandrels 22 are moved in the X-Y plane.

Depending upon the preceding customer order, the hopper 6 and cartridge8 containing cigarettes of the correct type for the first row of thecollation required for the customer order may not initially be at thefront station of the dispensing carousel 2. Similarly, where thecustomer has ordered a container of cigarettes comprising two differenttypes of cigarette, the cigarettes in one or more adjacent rows of therequired collation will inevitably be of different types. In this case,before the inserter rods are actuated to insert the first row ofcigarettes, or second of two dissimilar adjacent rows of cigarettes,into the split mandrel 22, the dispensing carousel 2 is indexed undercomputer control until a hopper 6 and cartridge 8 containing cigarettesof the correct type for the respective row is at the front station ofthe dispensing carousel 2.

It will be appreciated that if, for example, the ten hoppers 6 mountedon the two dispensing carousels 2 were to contain more than fivedifferent types of cigarettes, the hoppers 6 containing the correct typeof cigarettes for two dissimilar adjacent rows in any required collationmight be mounted on different dispensing carousels 2. In this case,before the second of the two dissimilar adjacent rows is inserted intothe split mandrel 22, the ball screw slide way 12 and vertical slide way18 are also driven to move the split mandrel 22 from one dispensingcarousel 2 to the other. The inserter rods associated with the latterdispensing carousel 2 are then actuated to push the cigarettes formingthe second of the two dissimilar adjacent rows into the split mandrel22.

Similarly, if a second detector in a hopper 6 supplied by a cartridge 8containing the correct type of cigarettes for the next row of therequired collation has informed the control system of the apparatus thatthe vanes of that hopper 6 are not full, the ball screw slide way 12 maybe driven to move the split mandrel 22 between the dispensing carousels2 and/or the dispensing carousels 2 may be indexed to position the splitmandrel 22 before a dispensing carousel 2 having an alternative hopper 6having vanes filled with the same type of cigarettes at the frontstation thereof.

As the columns of cigarettes formed between the vanes of the hoppers 6are fed under gravity down through the channels, the third set ofsensors inspect the tobacco and filter end of each cigarette therein. Ifthe third set of detectors identifies a defect at either end of acigarette, the control system of the apparatus records the position ofthe defective cigarette. When, in response to a customer order, a row ofcigarettes containing the defective cigarette is pushed out of thechannels of a hopper 6 at the front station 2 of a dispensing carousel 2by the reciprocating inserter rods, the control system interrupts thecollation forming process and instructs the ball screw slide way 12 tomove the carriage 14 away from the front station of the carousel 2, sothat the row of cigarettes is not inserted into the split mandrel 22,but falls into a reject tray or chute. Once the row of cigarettescontaining the defective cigarette has been rejected in this way, thecontrol system instructs the ball screw slide way 12 to drive thecarriage 14 back to the front station of the dispensing carousel 2 sothat a row of non-defective cigarettes may be inserted from the hopper 6into the split mandrel 22 by the inserter rods.

To avoid the need to reject a whole row of cigarettes in order to removea single cigarette identified as defective by the third set ofdetectors, the apparatus of FIGS. 1 and 2 may be provided withreciprocating inserter rods that can be actuated independently of oneanother. Alternatively, means may be provided for emitting blasts ofcompressed air separately from the ends of the reciprocating inserterrods in order to reject individual defective cigarettes.

Once the collation is complete, the ball screw slide way 12 is drivenunder computer control to move the carriage 14 to one end thereof,where, as described below, the split mandrel 22 transfers the completecollation of cigarettes to the first station of a horizontal, indexingturntable 26 mounted on the upper surface of the frame 4 at the end ofthe ball screw slide way 12.

As shown in FIG. 2, six recesses 28 are equally spaced in the uppersurface of the turntable 26, around the circumference thereof, such thatthe principal axes of the recesses 28 are radial of the turntable 26. Inuse, the turntable 26 indexes around clockwise as shown in FIG. 2 by thearrow, through six stations at which and between which packingoperations take place, as described below.

At the first station, immediately upstream of the end of the slide way12, four vertical magazines 30, each containing pre-formed lids for oneof the four types of container selectable by the customer, are mountedabout the periphery of the turntable 26, beneath the upper surface ofthe frame 24. In FIGS. 1 and 2 a portion of the sides of the frame 4 hasbeen removed to show the position of two magazines 30; for the sake ofsimplicity the other two magazines have been omitted from the Figures. Aseparate aperture 32 in the upper surface of the frame 4 is locatedabove each of the four magazines 30, through which upside downpre-formed lids are automatically delivered by the magazine 30. For thesake of simplicity only two of the four apertures 32 are shown in FIGS.1 and 2. Preferably, the inner surface of the pre-formed lids isprofiled to match the collation of cigarettes

On the upper surface of the frame 4 at the first station of theturntable 26, proximate the apertures 32, an extendible vertical gripperarm 34 is mounted for radial movement relative to the turntable 26.Following receipt of the customer order by the control system of theapparatus, the gripper arm 36 is actuated by, for example, a servo motorand driven under computer control to a position over the aperture 32above the magazine 30 containing pre-formed lids for the type ofcontainer ordered by the customer. Once in position, the gripper arm isextended to remove a pre-formed lid from the aperture 32 and thenretracted. The gripper arm 34 and removed pre-formed lid are drivenradially to a position over the turntable 26 where the gripper arm 34 isextended to place the lid upside down in an empty recess 28 in theturntable 26 at the first station.

The turntable 26 indexes clockwise to move the upside down liddownstream to the second station, at the end of the ball screw slide way12, where it receives the collation of cigarettes from the splitmandrels 22. The split mandrel 22 is driven by the ball screw slide way12 to a position over the upside down lid at the second station and the90° rotating valve, by which the split mandrel 22 is mounted to the arm20 of the turret 16, is actuated to move the split mandrel 22 to thesecond position in which the longitudinal axis thereof, and hence of thecollation of cigarettes therein, is vertical. Where, as in the presentexample, the split mandrel 22 contains a collation of filter cigarettes,the 90° rotating valve is operated so that when the split mandrel 22 isin the second position the filter ends of the cigarettes are nearest theframe 4.

Once the split mandrel 22 is in the second position, the vertical slideway 18 is driven to move the turret 16 and split mandrel 22 in theZ-direction towards the turntable 26 so that the collation of cigarettesis inserted filter end first into the upside down lid. The jaws 24 ofthe split mandrel 22 are then hinged opened to release the collation ofcigarettes and the vertical slide way 18 driven to raise the splitmandrel 22 clear thereof. A first horizontal gripper arm (not shown),which is fixedly mounted on the turntable 26, is operated to grasp thecollation of cigarettes just before it is released by the split mandrel22. The first horizontal gripper arm maintains its grip on the collationas the pre-formed container lid in which it is held is moved furtherdownstream from the second station to the third station by the indexingturntable 26.

Meanwhile, the jaws 24 of the split mandrel 24 are closed and the 90°rotating valve operated to return the split mandrel 22 to the firstposition, in which the longitudinal axis of the split mandrel 22 ishorizontal. The control system then drives the ball screw slide way 12,vertical slide way 18 and turret 16, as required, to position thecorrect split mandrel 22 for the following customer order in front ofone of the dispensing carousels 2 and the filing process described aboveis recommenced.

At the third station, four additional vertical magazines 36, eachcontaining pre-formed bodies for one of the four types of containerselectable by the customer, are mounted about the periphery of theturntable 26, beneath the upper surface of the frame 24. A separateadditional aperture (not shown) in the upper surface of the frame 4 islocated above each of the four magazines 36, through which upside downpre-formed bodies are automatically delivered by the magazine 36. Forthe sake of clarity not all of the additional magazines 36 have beenincluded in FIGS. 1 and 2. A moveable cartridge or cassette mountedbeneath a single aperture in the upper surface of the frame 4 mayalternatively be employed in the apparatus of FIGS. 1 and 2 to hold thepre-formed lids and/or pre-formed bodies for each type of availablecontainer, rather than the plurality of separate vertical cartridges 30,36 and separate apertures 32 and additional apertures.

An extendible vertical arm 38 is mounted on the upper surface of theframe 4 at the third station for radial movement relative to theturntable 26. On the end of the vertical arm 38, a cylindrical vacuumchamber 40 having a circumferential O-ring seal 42 disposed at its baseis mounted for movement in the Z-direction. A pneumatic vertical pusher(not shown) with a suction head is also mounted on the end of thevertical arm 38, within the vacuum chamber 40, for independent movementin the Z-direction relative thereto. The vertical arm 38 is actuated by,for example, a servo motor, and driven under computer control toposition the vacuum chamber 40 and pusher over the additional apertureabove the additional magazine 36 containing pre-formed bodies for thetype of container ordered by the customer. Once in position, the pusheris extended to place the suction head on the base of a pre-formedcontainer body, which is removed from the additional aperture as thepusher is retracted. Following retraction of the pusher, the arm 38 isdriven radially to move the vacuum chamber 40 and removed pre-formedcontainer body to a position over the turntable 26.

Once in position, the vertical arm 38 is extended to lower the vacuumchamber 40 onto the upper surface of the turntable 26 and the pushertherein is extended to lower the upside down pre-formed body over thecollation of cigarettes held in the pre-formed lid in the recess 28 inthe turntable 26 at the third station. As the vacuum chamber 40 and bodyof the container are lowered over the collation of cigarettes, thecollation is released by the first horizontal gripper arm mounted on theturntable 26.

Just before the pre-formed body is placed by the pusher onto the upsidedown pre-formed lid at the third station, the air within the vacuumchamber 40 is evacuated through a pipe in communication with the top ofthe vacuum chamber 40 and/or through an aperture in the turntable 26beneath the vacuum chamber 40. Once the pre-formed body has been placedonto the pre-formed lid at the third station, sealing the collation ofcigarettes within the container, the vacuum inside the vacuum chamber 40and the vacuum applied to the suction head of the pusher are released,the pusher retracted and the vertical arm 40 retracted to raise thevacuum chamber 40 clear of the sealed container 46.

As the turntable indexes further clockwise, the sealed container ofcigarettes 46 formed at the third station is moved downstream to afourth station where an automatic printing and labeling system 44 ismounted on the upper surface of the frame 4, next to the turntable 26.The printing and labeling system 44 is actuated by the control system togenerate a label showing information concerning the quantity and type ofcigarettes within the container and identifying the customer order,which is then applied by the system 44 to the surface of the container46 at the fourth station. The label applied to the container 46 maysimply identify the customer order using a unique identification numberassigned to the order by the control system. Preferably, however, whenordering the customized container of cigarettes the customer also entersa personalized graphic or verbal identifier at the terminal, which isthen printed on the label by the system 46. The software displayed bythe touch screen of the terminal may, for example, include a sub-menuthat presents the customer with a choice of pre-programmed graphicsymbols for selection and/or which allows the customer to enter theirname or initials.

Once the label has been applied to the container 46 by the automaticprinting and labeling system 44, the turntable 26 indexes clockwise tomove the container 46 downstream from the fourth station to the fifthstation where it is removed from the turntable 26 and placed the rightway up on the upper surface of the frame 4 for delivery to the customer.A second horizontal gripper arm 48 is mounted on the upper surface ofthe frame 4, about the periphery of the turntable 26 at the fifthstation, for rotational movement about a transverse axis. As it reachesthe fifth station, the container 46 is grasped by the second horizontalgripper arm 48, which is then rotated by 180° about the transverse axisto place the container 46 the right way up on the upper surface of theframe 4. The upright container 46 is released by the second gripper arm48 and delivered to the customer manually by the operator of theapparatus or automatically by means not shown.

Downstream of the second horizontal gripper arm 48, the apparatus shownin FIGS. 1 and 2 may further comprise, for example, an additionalautomatic printing and labeling system (not shown) for applying a taxstamp to the container 46 and/or a wrapper for applying a transparentover wrap to the container 46.

The entire apparatus shown in FIGS. 1 and 2 is preferably mounted behinda counter or bar (not shown) upon which, for example, video screens maybe mounted to advantageously display advertisements and/or otherinformation to customers. A customer preferably places their order usinga graphical touch screen system at a terminal mounted on the counter orbar.

The apparatus shown in FIGS. 1 and 2 is preferably operated by thecontrol system at a speed which is sufficiently slow to allow thecustomer to follow the individual manufacturing processes describedabove during production of their ordered customized container ofcigarettes. Depending upon the volume of customer orders received, thecontrol system may, however, adjust the speed of the apparatus to ensurethat length waiting times, which could result in a loss of customerinterest, are avoided. Preferably, the speed at which the apparatus isoperated is such that the time taken to produce each customizedcontainer of cigarettes is between 30 seconds and 2 minutes.

To increase the operating capacity of the apparatus of FIGS. 1 and 2,that is the length of time for which the apparatus may operate beforeempty cartridges 8 on the dispensing carousels 2 must be manuallyreplaced by an operator, an eight-station, indexing reservoir carouselmay be mounted above each dispensing carousel 2 for independent rotationabout the same vertical axis as the dispensing carousel 2. In use,additional, equally spaced, filled “stock” cartridges are mounted oneach of the two reservoir carousels at the seven stations thereof,leaving one station on each reservoir carousel empty.

When a second detector in a hopper 6 senses that the channels betweenthe vanes of that hopper 6 are empty, the control system instructs thedispensing carousel 2 on which the empty hopper 6 is located, and/or thereservoir carousel mounted above that dispensing carousel 2, to indexuntil the empty hopper 6 is positioned directly below the empty stationon the reservoir carousel. Once in position, the control system actuatesa transfer mechanism mounted on the reservoir carousel that includes,for example a reciprocating suction head, which removes the cartridge 8mounted above the empty hopper 6 and raises it into the empty station onthe reservoir carousel. The dispensing carousel 2 on which the emptyhopper 6 is located and/or the reservoir carousel are then indexed bythe control system until an additional cartridge on the reservoircarousel containing the same type of cigarettes as the removed cartridge8 is positioned directly above the empty hopper 6. Once in position, thesame or a corresponding transfer mechanism is actuated by the controlsystem to lower the additional cartridge onto the dispensing carousel 2above the empty hopper 6.

Either a single transfer mechanism, located at a particular station ofthe reservoir carousel, or a plurality of identical transfer mechanism,located at each station of the reservoir carousel, may be provided forreplacing cartridges 8 on the dispensing carousel 2 with additionalcartridges from the reservoir carousel. Furthermore, the content of theseven additional “stock” cartridges on the reservoir carousel mayadvantageously be matched to customer demand. For example, if customersshow a preference for two of the five cigarette brands available fromeach of the dispensing carousels 2, two additional cartridges containingeach of the two preferred brands of cigarette may be mounted on eachreservoir carousel, together with a single additional cartridgecontaining each of the other three brands.

To ensure that an additional cartridge containing the correct type ofcigarettes is lowered from the reservoir carousel into position above anempty hopper 6, a detector that reads identifying marks applied to therear of an additional cartridge is preferably mounted at each station ofthe reservoir carousel. Such detectors may be provided instead of, or inaddition to, the first set of detectors already described.

In the embodiment of the apparatus of the invention shown in FIGS. 1 and2, two five-station indexing dispensing carousels are provided. Inalternative embodiments, three or more indexing dispensing carousels, ora single dispensing carousel, having an increased or reduced number ofstations may be provided. Furthermore, instead of, or in addition to,multi-station dispensing carousels, embodiments of apparatus accordingto the invention may comprise two or more, spaced apart, fixed verticalhoppers between which the carriage 14 carrying the split hoppers 22 ismoved by the ball screw slide way 12. Where the apparatus of theinvention comprises a plurality of spaced apart, fixed hoppers, anindexing multi-station carousel is preferably mounted above each fixedhopper on which a plurality of filled cartridges of cigarettes may bemounted in order to increase the operating capacity of the apparatus.

During production of a customized container of cigarettes on theapparatus shown in FIGS. 1 and 2, a collation of cigarettes is placedfilter end first into an upside down pre-formed lid dispensed from amagazine 30 and then an upside down pre-formed body dispensed from anadditional magazine 36 placed over the collation of cigarettes, onto theupside down lid, to form the customized container of cigarettes. It willbe appreciated, however, that the customized container of cigarettescould alternatively be formed by, for example, similarly placing thecollation of cigarettes tobacco end first into a pre-formed bodydispensed from a magazine and then placing a pre-formed lid dispensedfrom a magazine over the collation of cigarettes, onto the body.

The collation of cigarettes for insertion into the container may beformed by removing rows of cigarettes, corresponding to the longitudinalrows of the collation, one at a time from the hoppers 6, as shown inFIGS. 1 and 2. Alternatively, the collation may be formed by removingrows of cigarettes, corresponding to the transverse rows of thecollation. For example, a collation of cigarettes for a containercomprising two rows of ten cigarettes could be prepared using theapparatus of FIGS. 1 and 2, by inserting ten rows of two cigarettes intoa split mandrel 22 positioned so that the shorter transverse axis of themandrel is horizontal.

Rather than being inserted into a collation mandrel, in embodiments ofthe method apparatus of the invention cigarettes removed from areservoir in response to a customer order may be placed directly into acontainer. For example, with reference to the apparatus shown in FIGS. 1and 2, rows of cigarettes could alternatively be pushed by the inserterrods from the channels of the hoppers 6 directly into pre-formedcontainer bodies or lids held in pairs of hinged jaws mounted on theends of the four arms 20 of the turret 16, in place of the splitmandrels 22. Where sealing of the container under vacuum is not desired,direct insertion of the cigarettes into a container may be preferred

An exploded view of an embodiment of a preferred type of container foruse with the apparatus of FIGS. 1 and 2 is shown in FIG. 3. Thecontainer comprises a deep drawn, flat-bottom, cylindrical aluminum body50 of oval cross-section. By oval here is meant a shape betweenrectangular and circular, having two parallel straight edges, the endsof which are joined by oppositely curved edges, that is, “stadium”shaped.

The body 50 is provided with a pair of elongate vertical protrusions 52on the outer surface of each of its straight parallel sides, proximatethe top thereof. In use, an injection moulded, laminar, polyethyleneinsert 54, having three spaced apart, upwardly extending, elongatetransverse steps 56 on its upper surface, is mounted within the body 50on the base thereof, before the body 50 is placed in one of theadditional magazines 36 of the apparatus of FIGS. 1 and 2

The container shown in FIG. 3 further comprises an injection moulded,high density polyethylene collar 58 having an oval cross-section of thesame shape as the body 50, which, in use, is mounted within the body 50.A vertical barrier (not shown) extends longitudinally between thecenters of the opposed curved ends of the collar 58, at the basethereof, dividing the interior of the collar 58 into two equally sizedcompartments.

In use, the compartments of the collar 58 receive two offset 4-6 nestedcollations of cigarettes from a split mandrel 22 having a centraldividing blade mounted between the hinged jaws 24 thereof. The innersurface of the jaws 24 of the split mandrel 22, the sides of thevertical barrier and the inner surface of the collar 58 inline with thevertical barrier are profiled to match the two offset 4-6 collations ofcigarettes.

An air and moisture impermeable, laminate, oval membrane 60 having a tabor flap 62 provided along a straight edge on its upper side is attachedabout its lower periphery to the upper edge of the collar 58 by, forexample, heat sealing or permanent adhesive. An oval, nitrile rubber(NBR) O-ring 64 is mounted around the outside of the collar 58 towardsthe base thereof.

The container further comprises a deep drawn, flat-top, cylindricalaluminum lid 66 of oval cross-section, which, in use, fits over theupper end of the body 50 and rests on the protrusions 52.

In order to fill the container shown in FIG. 3 using the apparatus ofFIGS. 1 and 2, the collar 58, with the membrane 60 and O-ring 64pre-mounted thereon, may be placed membrane end first into the lid 66,and the lid 66 and collar 58 then loaded into a magazine 30 of theapparatus shown in FIGS. 1 and 2. Preferably, however, only the collar58, with the membrane 60 and O-ring 64 pre-mounted thereon is loadedinto the magazine 30, so that it is delivered membrane end down throughan aperture 32 in the frame 4.

Cigarettes are pushed from the hoppers 6 into the split mandrel 22 toform the two offset 4-6 collations of cigarettes by the inserter rods aspreviously described. Preferably, the two rows of cigarettes on eitherside of the dividing blade of the split mandrel 22 are inserted from twodifferent hoppers 6 mounted on the dispensing carousels 2 so that thetwo offset 4-6 collations formed in the split mandrel 22 containdifferent brands of cigarette.

After they have been formed, the two offset 4-6 collations of cigarettesare placed filter end down into the two compartments of the collar 58 atthe second station of the turntable 26 and then the upside down body 50dispensed from the additional magazine 36, with the insert 52 mountedtherein, is placed over the them at the fourth station of the turntableas already described above.

Once the air within the vacuum chamber 40 at the fourth station has beenevacuated, the body 50 is pushed down over the collar 58 until the upperedge of the body 50 is flush with the membrane 60. As the body 50 ispushed over the collar 58, the O-ring 64 mounted thereon creates a sealbetween the outer surface of the collar 58 and the inner surface of thebody 50. Upon release of the vacuum inside the chamber 40, air is thusprevented from re-entering the body 50 of the container by the O-ringseal 64 and the impermeable membrane 60. In order to complete thecontainer, additional means (not shown), provided downstream of thesecond horizontal gripper arm 48, places the lid 66 over the upper endof the upright body 50, so that it rests on the protrusions 52.

The self-sealing of the body 50 and the collar 58 of the container undervacuum maintains the freshness of the two offset 4-6 collations ofcigarettes therein until the container is opened by the customer. Toopen the container, the customer first removes the lid 66 and then usesthe tab or flap 62 provided on the upper surface of the membrane 60 toat least partially remove the membrane 60 from the top of the collar 58to gain access to the cigarettes 68 within the container.Advantageously, the membrane 60 is affixed to the top of the collar 58using a re-sealable adhesive so that the customer may re-seal thecontainer during use.

As shown in FIG. 3, three cigarettes 70 in each of the two offset 4-6collations within the container are raised relative to other cigarettestherein by the steps 56 provided on the insert 54 mounted in the base ofthe body 50. Each step 56 raises two cigarettes 70, one from each 4-6collation, which are disposed adjacent to one another in the collar 58on opposite sides of the vertical barrier. In use, the six raisedcigarettes 70 may be easily removed by the customer allowing thecustomer easy access to the cigarettes in each of the offset 4-6collations. This is particularly advantageous where the two collationscontain different brands of cigarette. It will be appreciated that stepsor protrusions of different shape, size and/or position could beprovided at the base of the body 50 to raise a different number and/orgeometric arrangement of cigarettes within the container. It will alsobe appreciated that such steps or protrusions could, be provided, forexample, by embossing the base of the body 50 rather than by theinclusion of a separate insert 54.

Containers of the preferred type for use with apparatus of theinvention, exemplified by the container shown in FIG. 3, may have avariety of different shaped cross-sections, for example thecross-section may be square, rectangular, triangular or round, as wellas “stadium” shaped. It will be appreciated that the size of containersof the preferred type for use with the apparatus of the invention may bevaried to accommodate different numbers, collations and/or sizes ofcigarette.

The body 50 and/or lid 66 of the container shown in FIG. 3, and of otherembodiments of the preferred type of container for use with theapparatus of the invention, may be made from an injection mouldedplastic instead of aluminum. Preferably, where the body and/or lid ismade from plastic, a metal coating is applied to the outer surfacethereof by, for example, metal vapour deposition. Where containers ofthe preferred type are made from aluminum, the thickness of the walls ofthe containers is preferably about 0.2 mm.

It will be appreciated from the foregoing description of the inventionthat preferred embodiments of the apparatus thereof provide an automatedpack assembly with visual interest that allows the consumer topersonalize their smoking selection in a unique, customized pack offer.

1. Apparatus for the production of a customized container of differenttypes of cigarettes at a customer location, the apparatus comprising:reservoir means for storing the different types of cigarettes at thecustomer location; dispenser means for automatically removing apre-selected number of the different types of cigarettes from thereservoir means at the customer location in response to a customerorder; computer means for receiving a customer order at the customerlocation and to transmit the customer order to the dispenser means; andpacker means for automatically packing the removed pre-selected numberof the different types of cigarettes into a container at the customerlocation.
 2. The apparatus according to claim 1, wherein the packermeans further comprises a station at which the container is sealed. 3.The apparatus according to claim 1, wherein the packer means comprises asealing station at which the container is sealed under at least apartial vacuum.
 4. The apparatus according to claim 1, furthercomprising an inspection station at which at least one end of each ofthe pre-selected number of the different types of cigarettes removedfrom the reservoir means is inspected.
 5. The apparatus according toclaim 4, wherein the reservoir means is a hopper and the inspectionstation includes a plurality of optical sensors mounted between thevanes of the hopper.
 6. The apparatus according to claim 4, wherein theinspection station is coupled to the dispenser means so that cigarettesidentified by the inspection station as not meeting one or morepre-determined criteria are rejected prior to being packed in thecontainer by the packer means.
 7. The apparatus according to claim 1,further comprising a storage station at which two or more differenttypes of container at the customer location are stored.
 8. The apparatusaccording to claim 7, wherein the packer means comprises a movable armwhich automatically removes a container of a pre-selected one of the twoor more different types from the storage station in response to thecustomer order.
 9. The apparatus according to claim 1, comprising two ormore discrete reservoir means for storing the different types ofcigarettes at the customer location, each reservoir means beingseparately provided with a transfer mechanism which supplies cigarettesthereto.
 10. The apparatus according to claim 9, wherein each reservoirmeans is provided with a cartridge which supplies cigarettes of a singletype thereto.
 11. The apparatus according to claim 9, wherein eachreservoir means is provided with one or more removable cartridgessupplying cigarettes thereto.
 12. The apparatus according to claim 9,wherein the two or more discrete reservoir means are adapted to moverelative to the dispenser means.
 13. The apparatus according to claim 9,wherein each of the two or more discrete reservoir means is providedwith a separate dispenser means for removing which removes apre-selected number of the different types of cigarettes there from atthe customer location in response to a customer order.
 14. The apparatusaccording to claim 1, wherein the packer means comprises a collationmandrel which receives cigarettes removed from the reservoir means bythe dispenser means at the customer location, the collation mandrelbeing adapted to move relative to the dispenser means.
 15. The apparatusaccording to claim 1, wherein the computer means is provided with apre-programmed set of customer orders selectable by the customer.
 16. Amethod of producing a customised container of different types ofcigarettes at a customer location comprising: providing a reservoir ofthe different types of cigarettes at the customer location;automatically removing a pre-selected number of the different types ofcigarettes from the reservoir in response to a customer order; andpacking the removed pre-selected number of the different types ofcigarettes into a container.
 17. The method according to claim 16,further comprising sealing the container subsequent to the packing step.18. The method according to claim 16, further comprising sealing thecontainer under at least a partial vacuum.
 19. The method according toclaim 16, further comprising inspecting at least one end of each of thepre-selected number of the different types of cigarettes removed fromthe reservoir.
 20. The method according to claim 16, comprisingproviding two or more discrete reservoirs of the different types ofcigarettes at the customer location.
 21. The method according to claim16, comprising providing two or more discrete reservoirs of cigarettesat the customer location, each reservoir containing a single type ofcigarette.
 22. The method according to claim 16, comprising providingthe, or each, reservoir with a removable cartridge supplying cigarettesthereto.
 23. The method according to claim 16, comprising: providing twoor more reservoirs of containers at the customer location, eachreservoir containing a single type of container; automatically removinga pre-selected container from one of the two or more reservoirs inresponse to the customer order; and packing the removed pre-selectednumber of cigarettes into the removed pre-selected container.
 24. Themethod according to claim 16, further comprising collating thepre-selected number of cigarettes prior to packing them into thecontainer.